Roofing systems utilizing embedded decorative layer

ABSTRACT

A roof system for forming a roof includes a first layer positioned over a substrate, the first layer including a translucent material adapted to be exposed to weather, and a second layer positioned between the first layer and the substrate. The second layer is a decorative layer with decorative features such as, for example, an image, design, color, pattern, picture, fabric, or combinations thereof. The decorative features of the second layer are visible through the first layer.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims benefit of U.S. Provisional PatentApplication No. 63/147,863, filed Feb. 10, 2021.

INCORPORATED BY REFERENCE

The disclosure of U.S. Provisional Patent Application No. 63/147,863,filed Feb. 10, 2021, is incorporated by reference herein for allpurposes as if set forth in its entirety.

TECHNICAL FIELD

This disclosure relates generally to roofing systems and in particularto roofing systems utilizing a decorative layer.

BACKGROUND

Roofing materials, e.g., shingles, roofing membranes, roofing tiles,etc., sometimes use granules, aggregate materials, or colorants in acapping/weathering layer. However, such conventional capping materialsgenerally do not allow for much versatility for providing a wide varietyof patterns appearances, such as multivariate image patterning. Inaddition, metal roofing systems typically use capping paints to improveaesthetics, which also can provide for generally limited image designoptions. It can be expensive to achieve significant image patterning,including customizable patterns for such existing capping materials.

Accordingly, it can be seen that needs exist for roof systems that canprovide for greater variety of multivariate image, color patterning anddesigns, including customizable patterns and designs, for roofing andoutdoor systems, the present disclosure addresses these and otherrelated and unrelated issues.

SUMMARY

Briefly described, according to one aspect, a roof system includes asubstrate and a translucent layer positioned over the substrate thatreveals a plurality of decorative features. In one non-limitingembodiment, the roof system includes a first layer positioned over thesubstrate and comprising a translucent material adapted to be exposed toweather (e.g. wind, rain, snow, heat, cold, sunlight (includingultraviolet (UV) light, visible light, infrared (IR) light), hail andother impacts, etc. . . . ), and a second layer positioned between thefirst layer and the substrate. The second layer is a decorative layerwith decorative features including, but not limited to, an image,design, color, pattern, picture, fabric, or combinations thereof thatare visible through the first layer. In some non-limiting exampleembodiments, the roof system includes a translucent layer positionedover the substrate, and the translucent layer can include a decorativelayer or decorative features integrated therewith. For example, thetranslucent layer can comprise a polymer material and has decorativefeatures embedded, embossed, or otherwise integrated therewith, and thatare visible through the translucent layer.

In embodiments of the roof system, a decorative layer can be positionedbeneath a translucent layer that is adapted to be exposed to weather,and forms a weathering or capping layer for the roof system. In someembodiments, a decorative layer can be a coated substrate having aprotective coating such as a UV resistant coating. In one embodiment ofthe roof system, the decorative layer can be a base material which isfurther coated with a UV resistant translucent coating material orcapped with separate translucent roofing material, during production orduring installation. Embodiments of the present disclosure can providefor multivariate image, color patterning and design, that can provideease of installation such as by being capable of being rolled out over aroof deck, or applied as one or more individual sheets, panels, or asroofing shingles without generating significant additional cost forroofing and outdoor systems.

Various aspects of a roofing system including a translucent layer and adecorative layer and/or decorative features that are visible through thetranslucent layer include, without limitation a roof system, comprisinga substrate; a first layer positioned over the substrate, the firstlayer comprising a UV resistant translucent material adapted to beexposed to weather including varying environmental conditions such as,wind, rain, snow, temperature variations, sunlight (including UV light,visible light, IR light), hail or other impacts, etc., over time; asecond layer between the first layer and the substrate, the second layercomprising a UV resistant decorative layer including an image, design,color, pattern, picture, fabric, or combinations thereof; and aprotective layer applied along the second layer; wherein the decorativelayer is visible through the first layer.

In embodiments of the roof system, the first layer comprises a sheet orfilm of polypropylene, polyethylene, polyacrylate, polycarbonate,ethylene-vinyl acetate, silicone, polyvinyl fluoride, polyvinylchloride, polyurethane, polyvinylidene fluoride, fluorinated ethylenepropylene, or combinations thereof.

In embodiments of the roof system, the decorative layer is integratedwith the first layer and further comprises an extruded, woven, textured,embossed or patterned mat, fabric or sheet or combination thereof.

In embodiments, the second layer further comprises a plurality of lightsarranged along a lower surface of the second layer and configured toproject at least one image, color, design, pattern, or combinationsthereof, through the second layer so as to visible through the firstlayer.

In embodiments, the roof system further comprises a waterproof layerpositioned along the substrate and over which the first and secondlayers are received.

In embodiments, the roof system further comprises a vapor barrierapplied to the substrate.

In embodiments, the protective layer comprises a film, sheet or coatingapplied to a bottom surface of the second layer; and in someembodiments, the protective layer comprises a waterproof membrane.

In embodiments, the translucent material of the first layer furthercomprises a fire resistant material, an ultraviolet resistant material,impact resistant material, an antioxidant material, or combinationsthereof.

According to another aspect, a method, comprises moving a sheet oftranslucent polymer material along a processing path; applying adecorative layer to at least one side surface of the sheet oftranslucent polymer material, wherein the decorative layer comprises animage, pattern, design, color, picture, textured appearance, orcombinations thereof; applying a protective layer to the decorativelayer opposite the at least one side surface of the sheet of translucentpolymer material, the decorative layer comprising a UV resistantmaterial; and forming a plurality of roofing shingles from the sheet oftranslucent polymer material; wherein the roofing shingles each includean upper surface adapted to be exposed to weather, and wherein theimage, pattern, design, color photograph, textured appearance, orcombinations thereof of the decorative layer is visible through theupper surface of each roofing shingle.

In embodiments, applying the decorative layer to the sheet oftranslucent polymer material comprises printing, painting, etching,laminating, adhering, embedding, or embossing the image, pattern,design, color, picture, textured appearance, or combination thereofalong the at least one side surface of the sheet of translucent polymermaterial.

In embodiments of the method, the sheet of translucent polymer materialcomprises an extruded, woven, printed, colored, textured, or patternedmat, fabric, or sheet, or combination thereof.

In some embodiments, the method further comprises positioning aplurality of lights along the decorative layer; wherein the lights ofthe plurality of lights are selectively controllable to create an image,design, picture, video, color, pattern, or combination thereof, that isdisplayed through the upper surface of the sheet of translucent polymermaterial. In embodiments, inverse images, pictures, videos or otherdesigns can be projected onto the translucent layer and will be visibletherethrough.

In embodiments, the method further comprises positioning a plurality ofsolar cells along the decorative layer.

According to a further aspect, a roof system comprises: a substrate; atranslucent layer configured to be mounted along the substrate; adecorative layer applied to the translucent layer and including at leastone image, design, pattern, picture, textured appearance, color, orcombinations thereof; a protective layer along the decorative layer; anda waterproofing layer positioned between the substrate and thetranslucent layer; wherein the decorative layer comprises a UV resistantmaterial is visible through the translucent layer after the translucentlayer is mounted to the substrate.

In embodiments of the roof system, the translucent layer furthercomprises an extruded, woven, textured, embossed or patterned mat,fabric or sheet.

In embodiments of the roof system, the decorative layer is applied tothe translucent layer by embedding, embossing, adhering, etching,painting, dyeing, laminating, printing, or combination thereof.

In embodiments of the roof system, the translucent layer comprises asheet or film of polypropylene, polyethylene, polyacrylate,polycarbonate, ethylene-vinyl acetate, silicone, polyvinyl fluoride,polyvinyl chloride, polyurethane, polyvinylidene fluoride, fluorinatedethylene propylene, or combination thereof.

In embodiments of the roof system, the translucent layer furthercomprises a fire resistant material, an ultraviolet resistant material,impact resistant material, an antioxidant material, or combinationthereof.

In embodiments, the roof system further comprises a vapor barrierapplied to the substrate and configured to provide transmission of watervapor therethrough.

In other aspects, a roof system comprises: a substrate; a translucentlayer positioned over the substrate, the translucent layer comprising apolymer material and having a decorative features integrated therewith;wherein the decorative features comprise a color, an image, picture,texture, pattern, or combinations thereof, and are visible through thetranslucent layer; and a protective layer applied to a lower surface ofthe translucent layer, the protective layer comprising a polymer sheetand configured to be removable from the translucent layer.

In some embodiments, the decorative features comprise one or moreparticles, chips, dyes, tinting materials or combination thereof, mixedwith the polymer material of the translucent layer prior to formation oftranslucent layer.

In embodiments, the roof system further comprises a waterproof layerapplied to the substrate and over which the translucent layer ispositioned, and a vapor barrier layer positioned below the substrate.

In embodiments, the roof system further comprises an adhesive materialapplied to the lower surface of the translucent layer, and wherein theprotective layer is removed to expose the adhesive material prior to thepositioning of the translucent layer over the substrate.

In some embodiments, the roof system the decorative features comprise awoven or non-woven fabric or mat, chips, particles, picture, image,textured appearance or combinations thereof printed, painted, etched,laminated, adhered, embedded or embossed into the lower surface of thetranslucent layer.

Accordingly, embodiments of roofing materials, roofing systems andmethods for forming roofing materials that are directed to the abovediscussed and other aspects are disclosed. The foregoing and otheradvantages and aspects of the embodiments of the present disclosure willbecome apparent and more readily appreciated from the following detaileddescription and the claims, taken in conjunction with the accompanyingdrawings. Moreover, it is to be understood that both the foregoingsummary of the disclosure and the following detailed description areexemplary and intended to provide further explanation without limitingthe scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the embodiments of the present disclosure, areincorporated in and constitute a part of this specification, illustrateembodiments of this disclosure, and together with the detaileddescription, serve to explain the principles of the embodimentsdiscussed herein. No attempt is made to show structural details of thisdisclosure in more detail than may be necessary for a fundamentalunderstanding of the exemplary embodiments discussed herein and thevarious ways in which they may be practiced.

FIG. 1 shows a cross-sectional view of a roofing material of a roofsystem according to one embodiment.

FIG. 2 shows a cross-sectional view of a roofing material of a roofsystem according to another embodiment.

FIG. 3 shows a cross-sectional view of a roofing material of a roofsystem according to yet another embodiment.

FIGS. 4 a-4 c show example roofing materials according to aspects of thepresent disclosure.

FIGS. 5 a-5 b show example roofing materials according to additionalaspects of the present disclosure.

FIGS. 6 a-6 b show example roofing material according to another aspectof the present disclosure.

FIG. 7 shows an example roofing material according to yet another aspectof the present disclosure.

FIGS. 8 a-8 b show example roofing materials with solar panels accordingto further aspects of the present disclosure.

FIGS. 9 a-9 e show example roofing materials according to even furtheraspects of the present disclosure.

FIGS. 10 a-10 c show an example embodiment of a decorative or aestheticcolor pattern for forming a roofing material such as a sheet, membrane,panel, roofing shingle or tile according to principles of the presentdisclosure.

FIG. 11 is a photograph of a series of roofing shingles incorporating adesign such as shown in FIGS. 10 a-10 c installed on a roof for testingresistance of the roofing shingles when exposed to weather.

DETAILED DESCRIPTION

The embodiments of the present disclosure will now be described in moredetail with reference to the attached drawing figures.

FIGS. 1-11 show embodiments of a roof system 10 according to the presentdisclosure. The roof system 10 (FIGS. 1-3 ) comprises a roofing material11 that may comprise virtually any roofing material including, but notlimited to, roofing shingles, a roofing membrane, and roofing tiles toname a few. The roofing material 11 is configured to be positioned overa roof deck R of a roof, such as by being applied or otherwise placedonto an upper surface of the roof deck, and can be secured by adhesivesor sealant materials, fasteners, connectors, other attachments, orcombinations thereof. The roof system further is adopted to present adecorative appearance, including multivariate images, color patterning,designs, including customized or customer selectable patterns, designs,decorative feature or combinations thereof.

As indicated in FIGS. 1-3 , the roofing material 11 of the roof system10 generally includes a first layer or region 12 and a second layer orregion 14. In embodiments, the first layer 12 comprises a translucentlayer 16 comprising a translucent material 17 that is adapted to beexposed to weather or other external elements, for example, including,but not limited to an ability to withstand exposure to environmentalconditions such as exposure to wind, sunlight (including UV light,visible light and IR light), rain, snow, temperature variations (e.g.extreme cold and extreme heat), impacts from hail or other objects. Thesecond layer 14 comprises a decorative layer 18 including decorativefeatures or portions 18A including an image, design, color, pattern,picture, fabric, or combinations thereof. The second layer 14 ordecorative layer will be covered and protected by the first, translucentlayer with the decorative features 18A of the decorative layer visiblethrough the translucent layer 16 that forms the first layer 12. Inembodiments, as shown in FIGS. 4 a-10 c , the decorative features 18Acan include colored particles arranged into an image(s) or a geometricor random pattern(s); a material(s) capable of transitioning color whenviewed from different angles; light projected image(s), includinginverse images, videos, pictures, designs and combinations thereof;minimal heat generating light sources; active or dummy solar cells; amaterial(s) matching a solar panel color; or a construction material(s)(e.g., drywall, wallpaper, tile, plywood, glass, roofing membrane,etc.); or combinations thereof.

The translucent layer 12 (FIGS. 1-3 ) can comprise a sheet or film, orin some embodiments, a coating, of a durable waterproof material, e.g. amaterial that provides resistance to passage of water therethrough andwater shedding properties, facilitating flowing of water along theroofing material to deter ponding or pooling of water thereon. By way ofexample, and not limitation, in embodiments, the translucent layer cancomprise polypropylene, polyethylene, polyacrylate, polycarbonate,ethylene-vinyl acetate, silicone, polyvinyl fluoride, polyvinylchloride, polyurethane, polyvinylidene fluoride, fluorinated ethylenepropylene, or combinations thereof. In addition, or in the alternative,the translucent material 17 of the first, translucent layer 12 cancomprise a fire resistant material, an ultraviolet resistant material,impact resistant material, an antioxidant material, or combinationsthereof.

In some embodiments, the translucent layer 16 can have a thickness of 25mils to 250 mils, although other, greater or lesser thicknesses also canbe used. For example, but without limitation, in embodiments, thetranslucent layer can have a thickness of 10 mils to 500 mils, 10 milsto 400 mils, 10 mils to 300 mils, 10 mils to 250 mils, 10 mils to 200mils, 10 mils to 150 mils, 10 mils to 100 mils, 10 mils to 75 mils, 10mils to 50 mils, 10 mils to 25 mils, 25 mils to 50 mils, 25 mils to 75mils, 25 mils to 100 mils, 25 mils to 150 mils, 25 mils to 200 mils, 25mils to 250 mils, 25 mils to 300 mils, 25 mils to 350 mils, 25 mils to400 mils, 25 mils to 450 mils, and/or 25 mils to 500 mils.

In embodiments, the translucent layer, will exhibit a UV resistanceincluding resistance to loss of gloss, cracking, peeling, chalking, orloss of strength due to exposure to full spectrum sunlight (e.g., UVlight, visible light and infrared (IR) light), and extreme cold andelevated temperatures (e.g. temperatures below 0° F. and above 100° F.).The translucent layer also can have an impact resistance (e.g. anability to withstand an impact of 4.09 to 29.5 ft-lb/in² according toASTMD2794, ASTM D5628, and/or ASTM D6110.

In some embodiments, the translucent layer can have an impact resistanceof 4.0 to 30.0 ft-lb/in², 4.0 to 29.0 ft-lb/in², 4.0 to 28 ft-lb/in²,4.0 to 27.0 ft-lb/in², 4.0 to 26.0 ft-lb/in², 4.0 to 25.0 ft-lb/in², 4.0to 24.0 ft-lb/in², 4.0 to 23.0 ft-lb/in², 4.0 to 22.0 ft-lb/in², 4.0 to21.0 ft-lb/in², 4.0 to 20.0 ft-lb/in², 4.0 to 19.0 ft-lb/in², 4.0 to18.0 ft-lb/in², 4.0 to 17.0 ft-lb/in², 4.0 to 16.0 ft-lb/in², 4.0 to15.0 ft-lb/in², 4.0 to 14.0 ft-lb/in², 4.0 to 13.0 ft-lb/in², 4.0 to12.0 ft-lb/in², 4.0 to 11.0 ft-lb/in², 4.0 to 10.0 ft-lb/in², 4.0 to 9.0ft-lb/in², 4.0 to 8.0 ft-lb/in², 4.0 to 7.0 ft-lb/in², 4.0 to 6.0ft-lb/in², 4.0 to 5.0 ft-lb/in², 5.0 to 30.0 ft-lb/in², 5.0 to 29.0ft-lb/in², 5.0 to 28.0 ft-lb/in², 5.0 to 27.0 ft-lb/in², 5.0 to 26.0ft-lb/in², 5.0 to 25.0 ft-lb/in², 5.0 to 24.0 ft-lb/in², 5.0 to 23.0ft-lb/in², 5.0 to 22.0 ft-lb/in², 5.0 to 21.0 ft-lb/in², 5.0 to 20.0ft-lb/in², 5.0 to 19.0 ft-lb/in², 5.0 to 18.0 ft-lb/in², 5.0 to 17.0ft-lb/in², 5.0 to 16.0 ft-lb/in², 5.0 to 15.0 ft-lb/in², 5.0 to 14.0ft-lb/in², 5.0 to 13.0 ft-lb/in², 5.0 to 12.0 ft-lb/in², 5.0 to 11.0ft-lb/in², 5.0 to 10.0 ft-lb/in², 5.0 to 9.0 ft-lb/in², 5.0 to 8.0ft-lb/in², 5.0 to 7.0 ft-lb/in², 5.0 to 6.0 ft-lb/in², 6.0 to 30.0ft-lb/in², 6.0 to 29.0 ft-lb/in², 6.0 to 28.0 ft-lb/in², 6.0 to 27.0ft-lb/in², 6.0 to 26.0 ft-lb/in², 6.0 to 25.0 ft-lb/in², 6.0 to 24.0ft-lb/in², 6.0 to 23.0 ft-lb/in², 6.0 to 22.0 ft-lb/in², 6.0 to 21.0ft-lb/in², 6.0 to 20.0 ft-lb/in², 6.0 to 19.0 ft-lb/in², 6.0 to 18.0ft-lb/in², 6.0 to 17.0 ft-lb/in², 6.0 to 16.0 ft-lb/in², 6.0 to 15.0ft-lb/in², 6.0 to 14.0 ft-lb/in², 6.0 to 13.0 ft-lb/in², 6.0 to 12.0ft-lb/in², 6.0 to 11.0 ft-lb/in², 6.0 to 10.0 ft-lb/in², 6.0 to 9.0ft-lb/in², 6.0 to 8.0 ft-lb/in², 6.0 to 7.0 ft-lb/in², 7.0 to 30.0ft-lb/in², 7.0 to 29.0 ft-lb/in², 7.0 to 28.0 ft-lb/in², 7.0 to 27.0ft-lb/in², 7.0 to 26.0 ft-lb/in², 7.0 to 25.0 ft-lb/in², 7.0 to 24.0ft-lb/in², 7.0 to 23.0 ft-lb/in², 7.0 to 22.0 ft-lb/in², 7.0 to 21.0ft-lb/in², 7.0 to 20.0 ft-lb/in², 7.0 to 19.0 ft-lb/in², 7.0 to 18.0ft-lb/in², 7.0 to 17.0 ft-lb/in², 7.0 to 16.0 ft-lb/in², 7.0 to 15.0ft-lb/in², 7.0 to 14.0 ft-lb/in², 7.0 to 13.0 ft-lb/in², 7.0 to 12.0ft-lb/in², 7.0 to 11.0 ft-lb/in², 7.0 to 10.0 ft-lb/in², 7.0 to 9.0ft-lb/in², 7.0 to 8.0 ft-lb/in², 8.0 to 30.0 ft-lb/in², 8.0 to 29.0ft-lb/in², 8.0 to 28.0 ft-lb/in², 8.0 to 27.0 ft-lb/in², 8.0 to 26.0ft-lb/in², 8.0 to 25.0 ft-lb/in², 8.0 to 24.0 ft-lb/in², 8.0 to 23.0ft-lb/in², 8.0 to 22.0 ft-lb/in², 8.0 to 21.0 ft-lb/in², 8.0 to 20.0ft-lb/in², 8.0 to 19.0 ft-lb/in², 8.0 to 18.0 ft-lb/in², 8.0 to 17.0ft-lb/in², 8.0 to 16.0 ft-lb/in², 8.0 to 15.0 ft-lb/in², 8.0 to 14.0ft-lb/in², 8.0 to 13.0 ft-lb/in², 8.0 to 12.0 ft-lb/in², 8.0 to 11.0ft-lb/in², 8.0 to 10.0 ft-lb/in², 8.0 to 9.0 ft-lb/in², 9.0 to 30.0ft-lb/in², 9.0 to 29.0 ft-lb/in², 9.0 to 28.0 ft-lb/in², 9.0 to 27.0ft-lb/in², 9.0 to 26.0 ft-lb/in², 9.0 to 25.0 ft-lb/in², 9.0 to 24.0ft-lb/in², 9.0 to 23.0 ft-lb/in², 9.0 to 22.0 ft-lb/in², 9.0 to 21.0ft-lb/in², 9.0 to 20.0 ft-lb/in², 9.0 to 19.0 ft-lb/in², 9.0 to 18.0ft-lb/in², 9.0 to 17.0 ft-lb/in², 9.0 to 16.0 ft-lb/in², 9.0 to 15.0ft-lb/in², 9.0 to 14.0 ft-lb/in², 9.0 to 13.0 ft-lb/in², 9.0 to 12.0ft-lb/in², 9.0 to 11.0 ft-lb/in², 9.0 to 10.0 ft-lb/in², 10.0 to 30.0ft-lb/in², 10.0 to 29.0 ft-lb/in², 10.0 to 28.0 ft-lb/in², 10.0 to 27.0ft-lb/in², 10.0 to 26.0 ft-lb/in², 10.0 to 25.0 ft-lb/in², 10.0 to 24.0ft-lb/in², 10.0 to 23.0 ft-lb/in², 10.0 to 22.0 ft-lb/in², 10.0 to 21.0ft-lb/in², 10.0 to 20.0 ft-lb/in², 10.0 to 19.0 ft-lb/in², 10.0 to 18.0ft-lb/in², 10.0 to 17.0 ft-lb/in², 10.0 to 16.0 ft-lb/in², 10.0 to 15.0ft-lb/in², 10.0 to 14.0 ft-lb/in², 10.0 to 13.0 ft-lb/in², 10.0 to 12.0ft-lb/in², 10.0 to 11.0 ft-lb/in², 11.0 to 30.0 ft-lb/in², 11.0 to 29.0ft-lb/in², 11.0 to 28.0 ft-lb/in², 11.0 to 27.0 ft-lb/in², 11.0 to 26.0ft-lb/in², 11.0 to 25.0 ft-lb/in², 11.0 to 24.0 ft-lb/in², 11.0 to 23.0ft-lb/in², 11.0 to 22.0 ft-lb/in², 11.0 to 21.0 ft-lb/in², 11.0 to 20.0ft-lb/in², 11.0 to 19.0 ft-lb/in², 11.0 to 18.0 ft-lb/in², 11.0 to 17.0ft-lb/in², 11.0 to 16.0 ft-lb/in², 11.0 to 15.0 ft-lb/in², 11.0 to 14.0ft-lb/in², 11.0 to 13.0 ft-lb/in², 11.0 to 12.0 ft-lb/in², 12.0 to 30.0ft-lb/in², 12.0 to 29.0 ft-lb/in², 12.0 to 28.0 ft-lb/in², 12.0 to 27.0ft-lb/in², 12.0 to 26.0 ft-lb/in², 12.0 to 25.0 ft-lb/in², 12.0 to 24.0ft-lb/in², 12.0 to 23.0 ft-lb/in², 12.0 to 22.0 ft-lb/in², 12.0 to 21.0ft-lb/in², 12.0 to 20.0 ft-lb/in², 12.0 to 19.0 ft-lb/in², 12.0 to 18.0ft-lb/in², 12.0 to 17.0 ft-lb/in², 12.0 to 16.0 ft-lb/in², 12.0 to 15.0ft-lb/in², 12.0 to 14.0 ft-lb/in², 12.0 to 13.0 ft-lb/in², 13.0 to 30.0ft-lb/in², 13.0 to 29.0 ft-lb/in², 13.0 to 28.0 ft-lb/in², 13.0 to 27.0ft-lb/in², 13.0 to 26.0 ft-lb/in², 13.0 to 25.0 ft-lb/in², 13.0 to 24.0ft-lb/in², 13.0 to 23.0 ft-lb/in², 13.0 to 22.0 ft-lb/in², 13.0 to 21.0ft-lb/in², 13.0 to 20.0 ft-lb/in², 13.0 to 19.0 ft-lb/in², 13.0 to 18.0ft-lb/in², 13.0 to 17.0 ft-lb/in², 13.0 to 16.0 ft-lb/in², 13.0 to 15.0ft-lb/in², 13.0 to 14.0 ft-lb/in², 14.0 to 30.0 ft-lb/in², 14.0 to 29.0ft-lb/in², 14.0 to 28.0 ft-lb/in², 14.0 to 27.0 ft-lb/in², 14.0 to 26.0ft-lb/in², 14.0 to 25.0 ft-lb/in², 14.0 to 24.0 ft-lb/in², 14.0 to 23.0ft-lb/in², 14.0 to 22.0 ft-lb/in², 14.0 to 21.0 ft-lb/in², 14.0 to 20.0ft-lb/in², 14.0 to 19.0 ft-lb/in², 14.0 to 18.0 ft-lb/in², 14.0 to 17.0ft-lb/in², 14.0 to 16.0 ft-lb/in², 14.0 to 15.0 ft-lb/in², 15.0 to 30.0ft-lb/in², 15.0 to 29.0 ft-lb/in², 15.0 to 28.0 ft-lb/in², 15.0 to 27ft-lb/in², 15.0 to 26.0 ft-lb/in², 15.0 to 25.0 ft-lb/in², 15.0 to 24.0ft-lb/in², 15.0 to 23.0 ft-lb/in², 15.0 to 22.0 ft-lb/in², 15.0 to 21.0ft-lb/in², 15.0 to 20.0 ft-lb/in², 15.0 to 19.0 ft-lb/in², 15.0 to 18.0ft-lb/in², 15.0 to 17.0 ft-lb/in², 15.0 to 16.0 ft-lb/in², 16.0 to 30.0ft-lb/in², 16.0 to 29.0 ft-lb/in², 16.0 to 28.0 ft-lb/in², 16.0 to 27.0ft-lb/in², 16.0 to 26.0 ft-lb/in², 16.0 to 25.0 ft-lb/in², 16.0 to 24.0ft-lb/in², 16.0 to 23.0 ft-lb/in², 16.0 to 22.0 ft-lb/in², 16.0 to 21.0ft-lb/in², 16.0 to 20.0 ft-lb/in², 16.0 to 19.0 ft-lb/in², 16.0 to 18.0ft-lb/in², 16.0 to 17.0 ft-lb/in², 17.0 to 30.0 ft-lb/in², 17.0 to 29.0ft-lb/in², 17.0 to 28.0 ft-lb/in², 17.0 to 27.0 ft-lb/in², 17.0 to 26.0ft-lb/in², 17.0 to 25.0 ft-lb/in², 17.0 to 24.0 ft-lb/in², 17.0 to 23.0ft-lb/in², 17.0 to 22.0 ft-lb/in², 17.0 to 21.0 ft-lb/in², 17.0 to 20.0ft-lb/in², 17.0 to 19.0 ft-lb/in², 17.0 to 18.0 ft-lb/in², 18.0 to 30.0ft-lb/in², 18.0 to 29.0 ft-lb/in², 18.0 to 28.0 ft-lb/in², 18.0 to 27.0ft-lb/in², 18.0 to 26.0 ft-lb/in², 18.0 to 25.0 ft-lb/in², 18.0 to 24.0ft-lb/in², 18.0 to 23.0 ft-lb/in², 18.0 to 22.0 ft-lb/in², 18.0 to 21.0ft-lb/in², 18.0 to 20.0 ft-lb/in², 18.0 to 19.0 ft-lb/in², 19.0 to 30.0ft-lb/in², 19.0 to 29.0 ft-lb/in², 19.0 to 28.0 ft-lb/in², 19.0 to 27.0ft-lb/in², 19.0 to 26.0 ft-lb/in², 19.0 to 25.0 ft-lb/in², 19.0 to 24.0ft-lb/in², 19.0 to 23.0 ft-lb/in², 19.0 to 22.0 ft-lb/in², 19.0 to 21.0ft-lb/in², 19.0 to 20.0 ft-lb/in², 20.0 to 30.0 ft-lb/in², 20.0 to 29.0ft-lb/in², 20.0 to 28.0 ft-lb/in², 20.0 to 27.0 ft-lb/in², 20.0 to 26.0ft-lb/in², 20.0 to 25.0 ft-lb/in², 20.0 to 24.0 ft-lb/in², 20.0 to 23.0ft-lb/in², 20.0 to 22.0 ft-lb/in², 20.0 to 21.0 ft-lb/in², 21.0 to 30.0ft-lb/in², 21.0 to 29.0 ft-lb/in², 21.0 to 28.0 ft-lb/in², 21.0 to 27.0ft-lb/in², 21.0 to 26.0 ft-lb/in², 21.0 to 25.0 ft-lb/in², 21.0 to 24.0ft-lb/in², 21.0 to 23.0 ft-lb/in², 21.0 to 22.0 ft-lb/in², 22.0 to 30.0ft-lb/in², 22.0 to 29.0 ft-lb/in², 22.0 to 28.0 ft-lb/in², 22.0 to 27.0ft-lb/in², 22.0 to 26.0 ft-lb/in², 22.0 to 25.0 ft-lb/in², 22.0 to 24.0ft-lb/in², 22.0 to 23.0 ft-lb/in², 23.0 to 30.0 ft-lb/in², 23.0 to 29.0ft-lb/in², 23.0 to 28.0 ft-lb/in², 23.0 to 27.0 ft-lb/in², 23.0 to 26.0ft-lb/in², 23.0 to 25.0 ft-lb/in², 23.0 to 24.0 ft-lb/in², 24.0 to 30.0ft-lb/in², 24.0 to 29.0 ft-lb/in², 24.0 to 28.0 ft-lb/in², 24.0 to 27.0ft-lb/in², 24.0 to 26.0 ft-lb/in², 24.0 to 25.0 ft-lb/in², 25.0 to 30.0ft-lb/in², 25.0 to 29.0 ft-lb/in², 25.0 to 28.0 ft-lb/in², 25.0 to 27.0ft-lb/in², 25.0 to 26.0 ft-lb/in², 26.0 to 30.0 ft-lb/in², 26.0 to 29.0ft-lb/in², 26.0 to 28.0 ft-lb/in², 26.0 to 27.0 ft-lb/in², 27.0 to 30.0ft-lb/in², 27.0 to 29.0 ft-lb/in², 27.0 to 28.0 ft-lb/in², 28.0 to 30.0ft-lb/in², 28.0 to 29.0 ft-lb/in², 29.0 to 30.0 ft-lb/int.

In embodiments, the decorative layer 18 will comprise a UV resistantmaterial exhibiting a resistance to fading, cracking, loss of gloss,color stability when exposed to full spectrum sunlight (e.g. UV light,visible light and infrared (IR) light).

The roofing system 10 further will include a substrate 20 or base layer.As shown in FIGS. 2-3 , in embodiments, the substrate 20 can comprise aseparate, base layer below the second layer 14 (e.g. the decorativelayer 18) such that the second layer is positioned between the substrate20 and the first layer 12 (e.g. the translucent layer 16). In oneembodiment, as indicated in FIG. 1 , the decorative layer 18 can make upthe substrate 20 of the roofing material 11, in whole or in part, andmay include, but is not limited to, a mat, scrim, mesh or netting woveninto a geometric or randomized decorative lattice. The substrate furthercan include the decorative features or portions 18A, e.g., be colored orpainted, and will be visible through the translucent layer 12. Inaddition to or alternatively, the substrate 20 can comprise a deckingmaterial 21 (FIGS. 1-3 ) of the roof deck R over which the roofingmaterial 11 is applied.

As FIGS. 2-3 indicate, the roofing material 11 further can include anadditional substrate or base layer 20 over which the translucent layer16 and the decorative layer 18 are positioned (FIGS. 2-3 ). In thisregard, the translucent layer 16 and decorative layer 18 are configuredto be mounted along the substrate 20 such as by fasteners, adhesivematerials or other attachment. The decorative layer 18 will be visiblethrough the translucent layer 12 after the translucent layer 12 anddecorative layer 18 are mounted to the substrate 20.

FIGS. 2-3 further indicate that the decorative layer 14 can be locatedor positioned between the translucent layer 16 and the substrate 20. Forexample, the decorative layer 18 can be applied to the translucent layer16 by embedding, embossing, adhering, etching, painting, dyeing,laminating, printing, or combinations thereof. The decorative features18A of the decorative layer 18 will be visible through the first,translucent layer 16. The decorative layer 18 can have a thickness of 5mils to 250 mils, although other, greater or lesser thicknesses also canbe used. For example, but without limitation, in embodiments, thedecorative layer can have a thickness of 5 mils to 225 mils, 5 mils to200 mils, 5 mils to 175 mils, 5 mils to 150 mils, 5 mils to 125 mils, 5mils to 100 mils, 5 mils to 75 mils, 5 mils to 50 mils, 5 mils to 25mils, 1 mil to 10 mils, 1 mils to 25 mils, 1 mil to 50 mils, 1 mil to 75mils, 1 mil to 100 mils, 1 mil to 125 mils, 1 mil to 150 mils, 1 mil to175 mils, 1 mil to 200 mils, 1 mil to 225 mils, and/or 1 mil to 250mils.

The first and second layers 12/14, e.g. the translucent and decorativelayers 12/14, can be separate and distinct layers. However, inadditional or alternative, constructions, the translucent layer and thedecorative layer can be part of the same layer. That is, the decorativelayer, comprising one or more decorative features 18A, can be integratedwith the translucent layer. For example, as indicated in FIGS. 7-9 e thedecorative layer 18 can comprise a substrate 18B that can include anextruded, woven, textured, embossed or patterned mat, fabric or sheet,or combinations thereof integrated with the translucent layer. Inadditional example embodiments, the translucent layer can include apolymer material with decorative features 18A integrated therewith. Forexample, such decorative features can include colorful materials such asdies, printing, colored fibers or other components to further enhancethe visual appearance of the decorative layer.

In other embodiments, such illustrated in FIGS. 4 a-4 c the decorativefeatures 18 can include one or more particles, chips, dyes, or tintingmaterials received within the polymer material of the translucent layer16. In this regard, the decorative features 18A can be mixed orotherwise dispersed with the polymer material prior to formation of thetranslucent layer 16, e.g., prior to setting or hardening of the polymermaterial thereof. In some embodiments, as shown in FIGS. 6 a-6 b thedecorative features 18A can include a woven or non-woven orneedle-punched fabric, mat or strips, chips, particles, a picture orpictures, one or more images, a textured appearance, or combinationthereof. In other embodiments, as shown in FIGS. 5 a-5 b , thedecorative features can be adhered, embedded or embossed into the lowersurface 12A of the first layer 12 (e.g. translucent layer).

In addition, as indicated in FIG. 1 , the roof system 10 can include aprotective layer 22 applied along the decorative layer 18, and in someembodiments, integrated with the decorative and/or translucent layers(e.g. as part of a substantially integrated sheet of roofing material).The protective layer 22 can be applied to a bottom surface 14A of thedecorative layer 18, and can be left in place after installation of theroofing material. In embodiments, the protective layer 22 will comprisea film, sheet, or coating, such as a polymer sheet, applied to thebottom surface 14A of the decorative layer. In addition, or in thealternative, the protective layer 22 comprises a waterproof membrane.

In embodiments, the protective layer 22 is configured to be removablefrom the decorative layer 18 (or the integrated decorative andtranslucent layers). For example, the protective layer 22 can beconfigured to be removed, e.g., peeled or rolled off or otherwise takenaway, from the bottom surface 14A of the decorative layer to reveal anadhesive layer or portions of an adhesive material along the bottomsurface 14A. In this regard, as shown in FIG. 1 , an adhesive material24 is applied to the bottom surface 14A, such that the protective layer22 can be removed to expose the adhesive material 24 prior to thepositioning of the translucent and decorative layers over the substrate20. The adhesive material 24 can be configured to facilitate attachmentof the translucent and decorative layers to the substrate 20.

The protective layer 22 can comprise various protective coveringmaterials such as fabrics, mats, webs, mesh materials, and/or sheets,which can include, in some non-limiting examples, polypropylene,polyethylene, polyacrylate, polycarbonate, ethylene-vinyl acetate,silicone, polyvinyl fluoride, polyvinyl chloride, polyurethane,polyvinylidene fluoride, fluorinated ethylene propylene, or combinationsthereof. The protective layer 22 further can have a thickness of 5 milsto 100 mils, although other, greater or lesser thicknesses also can beused. For example, but without limitation, in various embodiments, theprotective layer can have a thickness of 5 mils to 150 mils, 5 mils to125 mils, 5 mils to 100 mils, 5 mils to 75 mils, 5 mils to 50 mils, 5mils to 25 mils, 1 mil to 10 mils, 1 mils to 25 mils, 1 mil to 50 mils,1 mil to 75 mils, and/or 1 mil to 100 mils.

FIGS. 2-3 further show an additional coating layer or region 30positioned or otherwise located between the translucent and decorativelayers 16/18 and the substrate 20. The additional, coating layer 30 caninclude a waterproofing layer that is positioned along the substrate 20and over which the translucent and decorative layers are received. Forexample, a top or upper surface 20A of the substrate 20 can be coatedwith a translucent water shedding or waterproofing coating 30. Thewaterproofing layer 30 can comprise asphalt, styrene butadiene styrene,polypropylene, polyethylene, polyacrylate, polycarbonate, ethylene-vinylacetate, silicone, polyvinyl fluoride, polyvinyl chloride, polyurethane,polyvinylidene fluoride, fluorinated ethylene propylene, or combinationsthereof, with or without a plasticizer or oils, and with or without afiller material.

The waterproofing layer 30, in some embodiments, can have a thickness of5 mils to 300 mils, although other, greater or lesser thicknesses alsocan be used. For example, but without limitation, in variousembodiments, the waterproofing layer can have a thickness of 5 mils to500 mils, 5 mils to 450 mils, 5 mils to 400 mils, 5 mils to 350 mils, 5mils to 300 mils, 5 mils to 250 mils, 5 mils to 225 mils, 5 mils to 200mils, 5 mils to 175 mils, 5 mils to 150 mils, 5 mils to 125 mils, 5 milsto 100 mils, 5 mils to 75 mils, 5 mils to 50 mils, 5 mils to 25 mils, 1mil to 10 mils, 1 mils to 25 mils, 1 mil to 50 mils, 1 mil to 75 mils, 1mil to 100 mils, 1 mil to 125 mils, 1 mil to 150 mils, 1 mil to 175mils, 1 mil to 200 mils, 1 mil to 225 mils, 1 mil to 250 mils, 1 mil to275 mils, 1 mil to 300 mils, 1 mil to 400 mils, and/or 1 mil to 500mils.

FIG. 3 shows that, in some embodiments, an additional coating layer orregion 32 further can be positioned along the substrate 20. The coatinglayer 32 can be position along an opposing side of the substrate 20 inrelation to the coating layer 30 and/or the translucent and decorativelayers. That is, the coating layer 32 can be applied over a bottom orlower surface 20B of the substrate (FIG. 3 ).

In one embodiment, the coating layer 32 includes a vapor barrier that isapplied to the substrate 20. The vapor barrier is configured to providetransmission of water vapor therethrough. In additional, or alternativeembodiments, the coating layer 32 can include a filled coating material,such as asphalt or filled polymer modified coating, which is nottranslucent.

The coating layer 32 can comprise a liquid coating, a sheet, film, orother coating material, which can include, without limitation, asphalt,styrene butadiene styrene, polypropylene, polyethylene, polyacrylate,polycarbonate, ethylene-vinyl acetate, silicone, polyvinyl fluoride,polyvinyl chloride, polyurethane or combinations thereof with or withouta plasticizer or oils, and with or without filler. The coating layer 32can have a thickness of 5 mils to 100 mils, although other, greater orlesser thicknesses also can be used. For example, but withoutlimitation, in various embodiments, the vapor barrier can have athickness of 5 mils to 150 mils, 5 mils to 125 mils, 5 mils to 100 mils,5 mils to 75 mils, 5 mils to 50 mils, 5 mils to 25 mils, 1 mil to 10mils, 1 mils to 25 mils, 1 mil to 50 mils, 1 mil to 75 mils, and/or 1mil to 100 mils.

In embodiments, the decorative features 18A of the decorative layer canalso comprise a plurality of lights or other lighted portions, which canbe used with existing decorative features 18A, or in place of suchdecorative features. The plurality of lights can be attached or embeddedinto the decorative layer and used to create various visual effects ordecorative features that will be visible through the translucent layer.In one embodiment, the plurality of lights can include minimal heatgenerating light sources, such as LEDs or other low heat light bulbs.The plurality of lights can be arranged along a lower surface of thedecorative layer 18 and can be configured and controlled to project atleast one image, video, picture, color, design, pattern, or combinationsthereof. In such embodiments, the roofing system 10 further can includea controller, such as a processor or control circuitry, that is operableto selectively control the plurality of lights to create an image,design, picture, video, color, pattern, or combinations thereof,displayed through the upper surface of the first or translucent layer.

FIGS. 4 a-4 c show some various examples of a roofing material 11according to aspects of the present disclosure. FIG. 4 a shows a roofingmaterial 11 with a mesh substrate 20 over which a first layer 12 and asecond layer 14 are applied, the second layer comprising a decorativelayer 18 including a color, e.g., white, as a decorative feature. FIGS.4 b-4 c show a roofing material 11 with a textured decorative layer 18including a color, e.g., brown or black, as further decorative features18A. In FIGS. 4 a-4 c , the roofing material 11 includes a translucentlayer 16 applied over the decorative layer.

FIGS. 5 a-5 b show roofing materials 11 according to other aspects ofthis disclosure. In FIGS. 5 a-5 b , the roofing materials 11 include afirst layer 12 comprising a translucent layer 16, and a decorative baseor second layer 14 comprising a decorative layer 18 including a printedimage or pattern as decorative features 18A. The decorative layer iscapped by the translucent layer 16, which comprises a translucentweathering film or coating, applied during manufacture or installationof the roofing material. In this regard, the decorative layer is appliedon one side of the translucent layer, with the translucent layer cappingthe decorative layer. FIG. 5 a shows an example of a translucent layercomprising amorphous poly alpha olefin (“APAO”) that caps a printeddecorative layer 18, e.g., a sheet with a design printed thereon, suchthat the decorative layer is sealed and protected from water and air. Inother embodiments, the translucent layer 16 can include other materials,such as for example, and not limitation, an FEP material that ispositioned over the decorative layer as a capping or weathering layer.The translucent layer of such an embodiment can be adhered to a printeddecorative layer 18, e.g., a sheet with a design printed thereon. Insuch embodiments, the translucent layer 16 may be loosely bonded to thedecorative layer 18 and not completely sealed. Other layers, e.g. one ormore protective layers also can be applied to such roofing material.

FIGS. 6 a-6 b show an example roofing material 11 according to anotherembodiment of the present disclosure. In FIGS. 6 a-6 b , the roofingmaterial 11 includes a decorative layer 18, which includes a painted matas decorative features 18A, that is coated with translucent layer 16,which includes a translucent polymer 17. The roofing material also hasdecorative features 18A including colored or dyed portions mixeddispersed with the translucent polymer, e.g., prior to formation of thetranslucent layer 12.

FIG. 7 shows a roof system 100 with a plurality of roofing materials 11,e.g., here shown in an embodiment as including roofing tiles, havingvarious, different decorative features 18A, e.g., different colors, andvarious different sizes and configurations that are arranged to providea patterned design 102 along a roof deck 104. In this embodiment, theroofing materials can be formed as sheets, panels, tiles or roofingshingles and can be arranged in different patterns to create a desireddecorative appearance. By way of example, FIG. 7 shows a rug patterndesign, with the roofing materials installed in a staggered or offsetgeometric design. While the roofing materials are shown in thisembodiment, and others in this disclosure, as rectangular of square,other shapes also can be used, including trapezoidal roofing shingledesigns (e.g. as shown in FIGS. 10 b -11) or other shapes.

FIGS. 8 a-8 b show example roofing materials 11 according to furtheraspects of the present disclosure. As indicated in FIGS. 8 a-8 b , insome embodiments, the roofing materials 11 can include a plurality ofactive or deactivated solar panels 200 positioned along the translucentor decorative layers. For example, in embodiments, the decorative layer18 can include the solar panels 200 as decorative features 18A of thedecorative layer, and the translucent layer 16 can be providedthereover.

FIGS. 9 a-9 e show various examples of decorative layers 18, e.g.,including printed laminate designs, according to embodiments of thepresent disclosure. These decorative layers can include printed designsor sheets that can have a pattern, including a repeating design, image,picture or pattern; or can have colors, textures and/or variationsthereof, including, for example, woven, non-woven, knitted,needle-punched or other textured fabrics or sheets, films or sheetsmolded, stamped, embossed, or otherwise formed with a textured orpatterned appearance. The decorative layers also can include multiplesublayers laminated together, or can include a base or sublayer withprinting, chips, particles, images, or other decorative features appliedtherealong.

In some embodiments, such as illustrated in FIGS. 10 a-10 c , roofingmaterial 11 can include a decorative layer 18 having repeating patternsor designs that can be printed or otherwise formed and applied inregister to a substrate, and can be laminated or otherwise applied oraffixed to the translucent protective layer 16 during formation of theroofing materials 11. By way of example, in addition to existingdesigns, colored or patterned materials, a customer or designer couldcreate a customized decorative pattern or design that can be used toform the decorative layer that is applied to or integrated with thetranslucent layer to form the roofing materials 11. As a further step ofthe method of forming decorative roofing materials, the roofingmaterials 11 can be cut to sizes and/or configurations for applicationto a roof deck, such as being be formed as sheets, panels, roofingshingles, tiles, shakes or other traditional roofing materials.

For example, as illustrated in FIGS. 10 b -11, in an embodiment, aseries of roofing shingles 300 having a toothed or other, similarconfigurations, such as Timberline® HDZ™ roofing shingles from GAF ofParsippany, New Jersey, can be formed, with each of the shinglesincorporating various portions of the design shown in FIG. 10 a . As aresult, a variety of installation options can be provided for forming aroof. Such installation patterns can enable or facilitate ease ofinstallation and/or removal of the roofing materials, as well as greatercustomization of the appearance of a roof.

For example, in embodiments, the roofing shingles 300 can be laid out invarious arrangements along a roof deck R. As shown in FIG. 11 , theroofing shingles 300 can be laid out in a pattern substantially matchingthe selected design; while in other embodiments, portions of thedecorative or aesthetic color patterns or designs created by theinstalled roofing shingles can be changed by orienting or disorientingadjacent roofing shingles during installation, such as illustrated inFIGS. 10 b and 10 c , and as a further alternative, in FIG. 11 . Variousmosaic patterns and other complex designs for creation of a decorativeroof appearance thus can be created or obtained for a given color sheetor design.

In other embodiments, the roofing materials 11 can be formed as sheetmaterials that can be rolled out over the roof deck and secured withadhesives and/or fasteners. The roofing materials also can be formed aspanels or individual sheets that can be positioned along the roof deckin varying arrangements.

In addition, in some embodiments, the look of a laminate roofing shinglecan be created without necessarily requiring laminating a backer to theroofing materials by cutting alternating small and wide roofingshingles. These small and wide roofing shingles then can be installedalong the roof deck adjacent one another in close proximity. Such aninstallation can lead to potential reductions in adhesive use. Stillfurther, by not laminating a backer to the roofing material, the needfor a nail zone also can be substantially reduced or minimized, which inturn further can help significantly increase installation speeds.

FIG. 11 illustrates an installation of roofing shingles 300incorporating the design of FIG. 10 a , with the roofing shinglesarranged along a roof deck. The roofing shingles 300 were laid out in arandom pattern and left on the roof deck and exposed to weather, e.g.exposed to varying environmental conditions such as sunlight (includingUV light, direct visible light, IR light), wind, rain, snow, substantialtemperature variations (e.g. elevated temperatures over 100° F. and coldtemperatures below 15° F.), hail or other impacts, etc., for a period ofa year. During that time, the installation was monitored and nonoticeable change in aesthetics or performance was found, e.g. nosubstantive incidence of haze, yellowness, color changes, loss of gloss,cracking, peeling, chalking, and/or changes in physical properties suchas brittleness and/or loss of impact strength due to exposure to fullspectrum sunlight (e.g., UV light, visible light and infrared (IR)light), and extreme cold and elevated temperatures (e.g. temperaturesbelow 15° F. and above 100° F. for over the one-year period.

The present disclosure also provides a method for forming a roofingsystem. The method includes moving a sheet of translucent polymermaterial along a processing path, and applying a decorative layer ordecorative features to at least one side surface of the sheet oftranslucent polymer material. The decorative layer or decorativefeatures can comprise an image, pattern, design, color, picture,textured appearance, or combinations thereof. In addition, the methodincludes applying a protective layer to the decorative layer oppositethe at least one side surface of the sheet of translucent polymermaterial. The method further includes forming a plurality of roofingshingles from the sheet of translucent polymer material. The roofingshingles each include an upper surface adapted to be exposed to weather,and wherein the image, pattern, design, color photograph, texturedappearance, or combinations thereof of the decorative layer is visiblethrough the upper surface of each roofing shingle.

In embodiments, applying the decorative layer to the sheet oftranslucent polymer material comprises printing, painting, etching,laminating, adhering, embedding, or embossing the image, pattern,design, color, picture, textured appearance, or combinations thereofalong the at least one side surface of the sheet of translucent polymermaterial. The sheet of translucent polymer material further can comprisean extruded, woven, printed, colored, textured, or patterned mat,fabric, or sheet.

Furthermore, in one embodiment, the method can include positioning aplurality of lights along the decorative layer. The plurality of lightsis selectively controllable to create an image, design, picture, video,color, pattern, or combinations thereof, displayed through the uppersurface of the sheet of translucent polymer material. In addition, or inthe alternative, the method further comprises positioning a plurality ofsolar cells along the decorative layer.

In some embodiments, the protective layer can have a gloss or an opacitythat can be selectively varied depending on a particular installation orapplication, such as installations with direct exposure to sunlight. Forexample, in embodiments, pigments, tinting agents and/or coatings can beadded to the translucent protective layer to provide the translucentprotective layer with an ability to substantially continuously adjust atint thereof depending on light angle and light intensity. In stillother embodiments, solar reflectance of the roofing materials can bevaried and/or improved based on selection of materials for thetranslucent protective layer and the decorative layer, and/or based onselection of colors or construction design of the translucent protectiveand decorative layers.

The present disclosure has been described herein in terms of examplesthat illustrate principles and aspects of the present disclosure. Theskilled artisan will understand, however, that a wide gamut ofadditions, deletions, and modifications, both subtle and gross, may bemade to the presented examples without departing from the spirit andscope of the present disclosure.

The invention claimed is:
 1. A roof system, comprising: a substrate; afirst layer positioned over the substrate, the first layer comprising atranslucent material adapted to be exposed to weather; a second layerbetween the first layer and the substrate, the second layer comprising adecorative layer including an image, design, color, pattern, picture,fabric, or combinations thereof; and a protective layer positioned alongthe second layer; wherein the decorative layer comprises an ultravioletresistant material; wherein the decorative layer is visible through thefirst layer; wherein the second layer comprises a plurality of lightsarranged along a lower surface of the second layer and configured toproject at least one image, color, design, pattern, or combinationsthereof, though the second layer.
 2. The roof system of claim 1, whereinthe decorative layer is applied to the first layer by embedding,embossing, adhering, etching, painting, dyeing, laminating, or printing.3. The roof system of claim 1, wherein the first layer comprises a sheetor film of polypropylene, polyethylene, polyacrylate, polycarbonate,ethylene-vinyl acetate, silicone, polyvinyl fluoride, polyvinylchloride, polyurethane, polyvinylidene fluoride, fluorinated ethylenepropylene, or combinations thereof.
 4. The roof system of claim 1,wherein the decorative layer is integrated with the first layer andfurther comprises an extruded, woven, textured, embossed or patternedmat, fabric or sheet.
 5. The roof system of claim 1, further comprisinga waterproof layer positioned along the substrate and over which thefirst layer and the second layer are received.
 6. The roof system ofclaim 5, further comprising a vapor barrier applied to the substrate. 7.The roof system of claim 1, wherein the protective layer comprises awaterproof membrane, film, sheet, coating, or combination thereof,applied to a bottom surface of the second layer.
 8. The roof system ofclaim 1, wherein the translucent material of the first layer furthercomprises a fire resistant material, an ultraviolet resistant material,impact resistant material, an antioxidant material, or combinationsthereof.
 9. A method, comprising: moving a sheet of translucent polymermaterial along a processing path; applying a decorative layer to atleast one side surface of the sheet of translucent polymer material,wherein the decorative layer comprises an ultraviolet resistant materialincluding an image, pattern, design, color, picture, texturedappearance, or combination thereof; positioning a plurality of solarcells along the decorative layer; applying a protective layer to thedecorative layer opposite the at least one side surface of the sheet oftranslucent polymer material; and forming a plurality of roofingshingles from the sheet of translucent polymer material; wherein theroofing shingles each include an upper surface comprising a translucentmaterial adapted to be exposed to weather, and wherein the image,pattern, design, color photograph, textured appearance, or combinationsthereof of the decorative layer is visible through the upper surface ofeach shingle.
 10. The method of claim 9, wherein applying the decorativelayer to the sheet of translucent polymer material comprises printing,painting, laminating, embedding, or embossing the image, pattern,design, color, picture, textured appearance, or combination thereofalong the at least one side surface of the sheet of translucent polymermaterial.
 11. The method of claim 9, further comprising positioning aplurality of lights along the decorative layer; wherein the plurality oflights is selectively controllable to create an image, design, picture,video, color, pattern, or combinations thereof, displayed through theupper surface of the sheet of translucent polymer material.
 12. A roofsystem comprising: a substrate; a translucent layer configured to bemounted along the substrate, the translucent layer comprising anultraviolet resistant polymer material; a decorative layer applied tothe translucent layer and including at least one image, design, pattern,picture, textured appearance, color, or combinations thereof; aprotective layer covering the decorative layer; and a waterproofinglayer positioned between the substrate and the translucent layer;wherein the decorative layer is visible through the translucent layerafter the translucent layer is mounted to the substrate; wherein thedecorative layer includes a plurality of lights arranged along thedecorative layer, the plurality of lights being selectively controllableto create an image, design, picture, video, color, pattern, orcombination thereof, displayed through the translucent layer so as to bevisible from an upper surface thereof.
 13. The roof system of claim 12,wherein the translucent layer further comprises an extruded, woven,textured, embossed or patterned mat, fabric or sheet.
 14. The roofsystem of claim 12, wherein the translucent layer comprises a sheet orfilm of polypropylene, polyethylene, polyacrylate, polycarbonate,ethylene-vinyl acetate, silicone, polyvinyl fluoride, polyvinylchloride, polyurethane, polyvinylidene fluoride, fluorinated ethylenepropylene, or combination thereof.
 15. The roof system of claim 12,wherein the translucent layer further comprises a fire resistantmaterial, an ultraviolet resistant material, impact resistant material,an antioxidant material, or combination thereof.
 16. The roof system ofclaim 12, further comprising a vapor barrier applied to the substrateand configured to provide transmission of water vapor therethrough. 17.A roof system comprising: a substrate; a translucent layer positionedover the substrate, the translucent layer comprising an ultravioletresistant polymer material and having a decorative features integratedtherewith; wherein the decorative features comprise a color, an image,design, picture, texture, pattern, or combinations thereof, and arevisible through the translucent layer; and a protective layer positionedalong a lower surface of the translucent layer, the protective layercomprising a polymer sheet and configured to be removable from thetranslucent layer; wherein the decorative features include a pluralityof solar cells.
 18. The roof system of claim 17, wherein the decorativefeatures comprise one or more particles, chips, dyes or tintingmaterials mixed with the ultraviolet resistant polymer material of thetranslucent layer prior to formation of the translucent layer.
 19. Theroof system of claim 17, further comprising a waterproof layer appliedto the substrate and over which the translucent layer is positioned, anda vapor barrier layer positioned below the substrate.
 20. The roofsystem of claim 17, further comprising an adhesive material applied tothe lower surface of the translucent layer, and wherein the protectivelayer is configured to be removable to expose the adhesive materialprior to positioning of the translucent layer over the substrate. 21.The roof system of claim 17, wherein the decorative features furthercomprise a woven or non-woven fabric or mat, chips, particles, texturedappearance or combination thereof printed, painted, etched, laminated,adhered, embedded or embossed into the lower surface of the translucentlayer.